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Simulation of corrugated plate heat exchanger for heat and flow analysis

Article  in  International Journal of Heat and Technology · March 2017

DOI: 10.18280/ijht.350127

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 INTERNATIONAL JOURNAL OF A publication of IIETA
HEAT AND TECHNOLOGY
ISSN: 0392-8764
Vol. 35, No. 1, March 2017, pp. 205-210
DOI: 10.18280/ijht.350127
Licensed under CC BY-NC 4.0 http://www.iieta.org/Journals/IJHT

Simulation of corrugated plate heat exchanger for heat and flow analysis
Muhammad Asif*, H. Aftab, H.A. Syed, M.A. Ali, P.M. Muizz

Faculty of Mechanical Engineering, GIK Institute of Engineering Sciences and Technology, Topi,
Swabi, KPK, 23640, Pakistan

Email: masif@giki.edu.pk

ABSTRACT

In this study thermal performance of corrugated plate heat exchanger (PHE) in single-phase flow is carried
out using the ANSYS CFX software. Aim of this research is to develop a generalized Nusselt Number
correlation for a commercial PHE configuration under single-phase flow for two different chevron angle
plates, 30o/30o and 60o/60o. The steady state simulation is carried out for a Reynolds number range of 500 to
2500, and the Prandtl number range of 3.5 to 7.5 is maintained in the simulation. The results showed that
Nusselt number is increased with increasing Reynolds number as well as by increasing the chevron angle.
However, Prandtl number showed trivial impact on the Nusselt number.

Keywords: Corrugated Plate Heat Exchanger, CFD Analysis, Heat and Flow Analysis, Nusselt Number
Correlation, Modified Wilson Plot.

1. INTRODUCTION century. The data reduction procedure for thermal

A heat exchanger is a device used for transferring heat
from one fluid to another. The fluid may not be allowed to
mix by separating them by a solid wall or they may be in
direct contact. They are operated in numerous industries such
as power generation, petroleum refineries, chemical and
processing plants and HVACs. There are various types of
heat exchangers available but our study pertains to the
corrugated plate heat exchangers (CPHE). It comprises of
multiple, thin plates, stacked upon each other. They have
large surface areas and corrugations to make the flow
turbulent for better heat transfer.
Numerous works has been done on Plate Heat Exchangers
(PHEs) and their data related to thermal and hydraulic
characterization are available in open literature. But there is a
widespread discrepancy in these reported correlations and
before commencing the present study, it was necessary to
analyze the experimental facilities and procedure, data
reduction methods, results and conclusions of some of the
important past works. Shah and Sekulic [1] presented a
comprehensive study on PHEs, including all characterization
related to PHEs and single pass gasketed PHEs. The
procedure of installing the PHEs in vertical configuration
along with many other important aspects related to PHEs has
been presented. In our study, the analysis technique for
determining the core pressure drop and friction factor is used
from the work described by Shah and Sekulic [1]. Fernandez-
Seara et al. [2] have provided a detailed review on the
original Wilson Plot, number of its modifications and
application to different heat exchangers over the last half
performance adopted by Khan et al. [3] is used in the current
study. This procedure requires the Reynolds Number (Re) to
be kept constant on both hot and cold sides and assume the
heat transfer coefficient on both sides to be same. Based on
this data reduction procedure, two correlations have been
proposed for two different chevron angle (β) configurations;
30°/30°, and 60°/60°. The Nusselt Number (Nu) is reported
to increase with β and with Reynolds number. The friction
factor (f) decreases with Re but increases with β [4].
Although, Hashmi et al. [5] used similar data reduction
method i.e. a Modified Wilson Plot Technique, but Nu
correlation for the mixed plate configuration (β = 30°/60°)
was reported only. Muley and Manglik [6] provided the
comprehensive set of pressure drop correlations for PHEs
using the Wilson Plot Technique . However, the effect of
elevation pressure drop was ignored in friction factor
calculations. Akturk et al. [7] presented Nu and f correlations
only for the 30°/30°plate configuration. Although the trends
presented is comparable with literature but the Nu versus Re
plots does not represent a linear relation. Turk et al. [8]
developed correlations to analyze the thermal and hydraulic
performance of gasketed plate heat exchangers (GPHE) for a
Reynolds’s number range of 500-5000. Quintero and Vera [9]
presented exact solution for wall conduction effects in
counter-flow parallel plate heat exchange in the laminar flow
regime. The maldistribution of chevron angle, flow
distribution and pressure drop in plate heat exchanger was
analyzed by Kumar and Singh [10], while the impact of
fouling on heat transfer performance was described by Hazmi
et al. [11]. The effect of various nano-fluids on heat transfer

205
capacity of plate heat exchanger is presented by Doohan et al.
[12] by energy and exergy analysis. Zhang et al. [13]
predicted the correlations of friction factor and Nusselt
number for capsule type plate heat exchanger. Whereas
Wahiba et al. [4] carried out 3D CFD analysis of plate fin
tube heat exchanger to predict the effect of inlet air flow
maldistribution on design and thermal-hydraulic performance.
In the published literature of PHEs, references [1] and [14]
have presented the detailed characterization of PHEs and
experimental conditions. Others have missed several
important geometric and experimental parameters. Moreover,
they have used the same value of the corrugation depth (b)
for both the configurations (30°/30°, and 60°/60°) during
their experimentation, whereas in fact it varies in both
configurations, being the highest for soft configuration and
lowest for the hard plate configuration. In this study
configurations of Nusselt number for the configurations
(30°/30°, and 60°/60°) is developed for for a Reynolds’s
number range of 500 to 2500 and the Prandtl number range
of 3.5 to 7.5.
2. DESIGN OF HEAT EXCHANGER
2.1 Details of corrugated plates
The corrugated plates are the main components of the
simulation. The chevron angle, corrugation depth and
corrugation pitch varied for the two types of plates used. The
modular design of the heat exchanger allowed us to arrange
the plates in the required configurations. The plate geometry
used in the simulation is shown in Figure 1. The dimensional
characteristics of chevron plate are shown in Table 1, while
the geometric characteristics of chevron plate are shown in
Table 2.
Figure 1. Basic geometric characteristics of Chevron Plate
Table 1. Dimensional characteristics of Chevron Plate
Geometric Characteristics Measurement
Width of the plate, Lw (mm) 185
Height between centres of ports, Lv (mm) 565
Port diameter, Dp (mm) 43
Horizontal distance between centres of
125
ports, Lh (mm)
Mean channel spacing, b (mm) 2.2 and 3.6a
Plate thickness, t (mm) 0.5
Effective area of plate, A (m2) 0.095
Corrugation pitch, Pc (mm) 13.25 and 6.25b
Surface enlargement factor, j 1.117
a
for  = 60o/60o plate configurations
b
for  = 30o/30o plate configurations
206
Table 2. Geometric characteristics of chevron plate
Characteristics Description
It is a measure of softness (small β, low
thermal efficiency and pressure drop) and
hardness (large β, high thermal efficiency
Chevron angle, β and pressure drop) of thermal and hydraulic
characteristics of plates. Some authors define
π/2-β as the chevron angle. β typically varies
from 20o to 65o.
Ratio between the developed area (based on
Surface
corrugation pitch, Pc, and plate pitch, p) and
enlargement
the projected area (viz. LwxLp, where Lw =
factor, Ø
Lh + Dp and Lp = Lv – Dp)
Corrugation depth
b = p – t, the difference between plate pitch,
or mean channel
p & plate thickness, t.
spacing, b
Ax is the minimum flow area between the
Channel flow plates and is determined as the product of
area, Ax width and depth of the plate configurations
(i.e. Ax = b x Lw)
Dh is defined as four times the ratio of
Channel hydraulic minimum flow area to wetted perimeter,
diameter, 𝐷ℎ =
2𝑏𝐿𝑤 Since b << Lw, Dh is generally
Dh 𝑏 + 𝐿𝑤∅ taken to be 2b/j.
2.2 CAD models
In order to perform simulations, we need to build a CAD
model. The measurements for the different geometric
parameters mentioned in Table 1 and Table 2 are used to
design a computer generated model using the PTC Creo
Parametric software (version 3.0). The outer part for both the
plates are same, only the corrugated portion of the plates is
different for both the 30o and 60o plates, and therefore two
different corrugations configurations are designed.
2.2.1 60o/60o chevron angle
The corrugations are sinusoidal and therefore a Cartesian
coordinate system is set and the following equation is used to
generate the curve in Creo Parametric:
The corrugations are sinusoidal and therefore a Cartesian
coordinate system is set and the following equation is used to
generate the curve in Creo Parametric:
𝑥 = 6.25 ∗ 𝑡
𝑦 = 1.1 sin(360𝑡)
𝑧=0
This equation was repeated more than 62 times to get
corrugated sinusoidal curves as on the actual 60o/60o plate.
The Curve was projected in the sketch mode to obtain its
sketch, which was extruded to obtain a rectangular
corrugated plate while maintaining the thickness of the plate
at 0.5 mm. The plate was cut using remove material extrusion
to obtain one half of the actual trapezoidal corrugated plate
matching the exact dimensions mentioned above. This part
was mirrored to obtain the other exact half and the CAD
model of the final corrugated plate was obtained.
2.2.2 30o/30o chevron angle
Similar procedure was used to design the 30 o/30o plate.
Only the equations were changed which are as follows:
𝑥 = 13.25 ∗ 𝑡
𝑦 = 1.8 sin(360𝑡)
𝑧=0 temperature for a given fluid. We evaluated the average
required temperature for different Prandtl number.
These equations were repeated more than 28 times to get
corrugated sinusoidal curves as on the actual 30o/30o plate.

3. CFD ANALYSIS

After building both the CAD models, the next step was to
run simulations by varying the flow and heat conditions,
hence the Reynolds and Prandtl numbers, and to record the
output results. The ANSYS CFX software (version 16.1) is
used to perform simulation. The following procedure is
adopted to prepare the models for simulation. Figure 2. Mesh of 30°
/30°plate on ICEM CFD Ansys

3.1 Mesh formation

The IGS file from Creo Parametric was imported to ICEM

CFD to create the mesh. The mesh was created only for the
corrugated portion of the heat exchanger. The first process
was to create the outer surfaces for the domain where the
fluid has to flow. The surface was created using 2-4 curves Figure 3. Mesh quality of 30°
/30°plate
method. The inlet, outlet and other boundaries were named
while creating parts using the surfaces created before. The
inlet and outlet of hot and cold fluids were named such that
the fluid flows in the counter-flow direction. The hot and
cold bodies were created by using all the relevant surfaces to
enclose the domain.

3.1.1 Mesh for 30o/30o Plate

Free mesh was created by assigning the part size, height
and height ratio equal to 1. The unnecessary holes were
closed before creating the mesh. Flood fill was carried out
after the formation of mesh to ensure that the two domains Figure 4. Mesh of 60°
/60°plate on ICEM CFD Ansys
don’t mix with each other. The mesh and its quality are
shown in Figure 2 and Figure 3 respectively.

3.1.2 Mesh for 60o/60o plate

Free mesh was created by assigning the part size and
height equal to 1.3. The quality of mesh was compromised in
order to reduce the number of mesh elements as we used
academic Ansys which limits the number of elements. A
flood fill was carried out after the mesh was created to ensure
that the two domains don’t mix with each other. The mesh
and its quality are shown in Figure 4 and Figure 5
respectively.
3.2 Setting of parameters
After the formation of mesh, the cfx5 file was imported to
CFX Pre where the fluids were defined and the thermal
parameters were set. The inlet and outlet port were selected
from the list of surfaces created during the mesh formation.
An interface of stainless steel having thickness of 0.5mm was
defined between the two fluids so that the fluids don’t mix
during simulation. Shear Stress Model was adopted for the
simulation.
3.2.1 Determination of inlet condition
The inlet temperature and velocity were determined
according to the required Reynolds Number which varied
from 500 to 2500 for hot water. Since, we had to vary the
Prandtl number from 3.5-7.5 which varies by the average
Figure 5. Mesh quality of 60°
/60°plate
Then we assumed the initial temperature of hot fluid such
that the average of inlet and outlet temperature becomes
equal to the required temperature. Several iterations were
required to determine the correct inlet temperature and
velocity.
3.3 Simulations and recording of results
After the setting of the parameters, the ANSYS Solver
Manger was opened and the required case file was loaded.
The simulations were set to run in local parallel using 4
partitions. All simulations of different inlet conditions were
carried out in the same way. The results of simulations were
recorded using ANSYS CFX Post. The values of inlet
pressure, outlet pressure, outlet temperature and mass flow
rate were determined for both the hot as well as the cold
fluid. The temperature contour and streamlines of 30°/30°
configuration is shown in Figure 6 and Figure 7, respectively.
While for 60°/60°configuration, the temperature contour and
streamlines are shown in Figure 8 and Figure 9, respectively.

207
 4. DATA REDUCTION

The data is reduced to obtain the required correlations of

Nusselt number and Reynolds number.

4.1 Modified Wilson plot method

This method is used to obtain the multiplier and exponent

of Reynolds number in the following generalized Nusselt
number correlation

0.14
μ
Nu=CRe𝑚 Prn. ( ) (1)
μs

C, m and n are independent of the nature of fluid used.

Figure 6. Temperature contour of 30°
/30°plate at Re = 500, The heat transfer coefficients for the cold and hot sides of
Pr = 3.5 PHE are obtained by the following equations, respectively
1
𝑝 𝜇
ℎ𝑐= 𝑘𝑐 𝑐𝐶 𝑅𝑒𝑐 𝑃𝑟𝑐3 ( ).13 (2)
𝐷ℎ𝑦𝑑 𝜇𝑠
.

1
𝑝 𝜇
ℎ 𝑘 𝐶ℎ 𝑅𝑒ℎ 𝑃𝑟ℎ3 ( ).13 (3)
ℎ=𝐷 ℎ 𝜇𝑠
ℎ𝑦𝑑
.

These two results are then plugged in the following

equation
1 1 𝑡 1
= + ( )𝑤 + (4)
𝑈 ℎ𝑐 𝑘 ℎℎ

Figure 7. Streamlines of 30°

/30°plate at Re = 500, Pr = 3.5 By solving, we obtained the following equations

1 𝑡 1 1
−( ) = 1 + 1 (5)
𝑈 𝑘 𝑤 𝑘 𝑝 𝜇 .14 𝑘 𝑝 𝜇
𝐶𝑐 𝑐 𝑅𝑒𝑐 𝑃𝑟𝑐3 ( ) 𝐶ℎ ℎ 𝑅𝑒ℎ 𝑃𝑟ℎ3 ( ).14
𝐷ℎ𝑦𝑑 𝜇𝑠 𝐷ℎ𝑦𝑑 𝜇𝑠

1
1 𝑡 𝑘ℎ 𝜌𝑣𝐷ℎ𝑦𝑑 𝑝 𝐶𝑝 𝜇 ⁄3 𝜇 0.14 1
(𝑈 − (𝑘) ) [𝐷 ( 𝜇
) ( 𝑘
) (𝜇 ) ]=𝐶 +
𝑤𝑎𝑙𝑙 ℎ𝑦𝑑 ℎ ℎ 𝑠 ℎ ℎ
𝑝 1
𝑘ℎ 𝜌𝑣𝐷ℎ𝑦𝑑 𝐶𝑝 𝜇 ⁄3 𝜇 0.14
( ) ( ) ( )
𝐷ℎ𝑦𝑑 𝜇 ℎ 𝑘 ℎ 𝜇𝑠 ℎ
𝑝 1⁄ (6)
𝑘 𝜌𝑣𝐷ℎ𝑦𝑑 𝐶 𝑝 𝜇 3 𝜇 0.14
𝐶ℎ 𝑐 ( ) ( ) ( )
𝐷ℎ𝑦𝑑 𝜇 𝑐 𝑘 𝑐 𝜇𝑠 𝑐

This equation is then compared to the general equation of

slope
Figure 8. Temperature contour of 60°
/60°plate at Re = 500,
Pr = 3.5 𝑌1 = 𝑚𝑋1 + 𝑏 (7)

where
1⁄
1 𝑡 𝑘ℎ 𝜌𝑣𝐷ℎ𝑦𝑑 𝑝 𝐶𝑝 𝜇 3 𝜇 0.14
𝑌1 = ( − ( ) )[ ( ) ( ) ( ) ] (8)
𝑈 𝑘 𝑤𝑎𝑙𝑙 𝐷ℎ𝑦𝑑 𝜇 ℎ 𝑘 ℎ 𝜇𝑠 ℎ

𝑝 1
𝑘ℎ 𝜌𝑣𝐷ℎ𝑦𝑑 𝐶𝑝 𝜇 ⁄3 𝜇 0.14
( ) ( ) ( )
𝐷ℎ𝑦𝑑 𝜇 ℎ 𝑘 ℎ 𝜇𝑠 ℎ
𝑋1 = 𝑝 1 (9)
𝑘𝑐 𝜌𝑣𝐷ℎ𝑦𝑑 𝐶𝑝 𝜇 ⁄3 𝜇 0.14
𝐶ℎ ( ) ( ) ( )
𝐷ℎ𝑦𝑑 𝜇 𝑐 𝑘 𝑐 𝜇𝑠 𝑐

1
slope: 𝑚=
𝐶ℎ
1
intercept: 𝑏=
𝐶𝑐

Figure 9. Streamlines of 60°

/60°plate at Re = 500, Pr = 3.5

208
 X1 & Y1 are calculated from the data obtained from 0.14
μ
simulations and value of exponent ‘p’ is assumed initially. Nu=0.093Re0.7106 Pr1.3 ( ) β= 30°/30° (22)
μs
Using X1 and Y1, the plot is made and values of slope (m)
and intercept (b) can be determined. 0.14
μ
Nu=0.112Re0.714 Pr1.3 ( ) β=60°/60° (23)
μs
4.1.1 Logarithmic modification
The logarithmic modification of equation (6) is given
below:

1 t 1
( −( ) )= k p 1⁄ μ 0.14
+
U k wall Ch h Reh Prh 3 ( )
Dhyd μs h
1
kc p 1
⁄ μ 0.14
(10)
Cc Rec Prc 3 ( )
Dhyd μs c

1 𝑡 1 1⁄ 𝜇 0.14 𝐾𝑐 1
3 Figure 10. Linear Plot for 30/30 plate at Pr = 7.5
( − − 1⁄ 𝜇 0.14 𝐾 ) 𝑃𝑟ℎ ( ) = 𝑝 (11)
𝑈 𝑘 𝑝
[𝐶𝑐 𝑅𝑒𝑐 𝑃𝑟𝑐 3 ( ) 𝑐
] 𝜇𝑠 𝑐 𝐷ℎ (𝐶ℎ 𝑅𝑒ℎ )
𝜇𝑠 𝑐 𝐷ℎ

𝑋2 = ln(𝑅𝑒ℎ ) (12)
1
𝑦2 = 𝑝 (13)
(𝐶ℎ 𝑅𝑒ℎ )

𝑌2 = 𝑙𝑛𝑦2 = −𝑙𝑛𝐶ℎ − 𝑝𝑙𝑛(𝑅𝑒ℎ ) (14)

4.1.2 Iterative procedure

Procedure for finding the values of ‘p’ and ‘Ch’ is given Figure 11. Logarithmic plot for 30/30 plate at Pr = 7.5
below:
1. An initial value of ‘p’ is assumed and put in X1,Y1
plot
2. The plot of equation 2 & 3 will give us values of ‘Ch’
and ‘Cc’.
3. Plug in these values of ‘Ch’ and ‘Cc’ and plot X2, Y2.
4. Plot of X2 and Y2 will yield new value of p.
5. Repeat this iteration until the difference of the
previous value and the present value becomes ≤0.02 which is
our

Figure 12. Linear plot for 60/60 plate at Pr = 4.5

5. RESULTS

Using the simulation results and Modified Wilson, the

constant multiplier (C) and the exponent (p) of Re are
determined for each of the plate configuration data. The
Prandtl Number (Pr) exponent is taken to be 1/3 because
literature reveals that its value tends to remain between 0.3
and 0.4. This effect is further investigated below. The
classical value of 0.14 is used for the exponent of (μ/μ s).

5.1 Modified Wilson plots

For 30/30 configuration, the Wilson plot of X1 vs. Y1 at
Pr=7.5, is shown in Figure 10, while plot of X2 vs. Y2 at
pr=7.5 is shown in Figure 11. The slope of X2 vs. Y2 gives
the reciprocal of exponent of the Reynolds number and the
intercept gives the value of reciprocal of Ch. Likewise, for
60/60 configurations, the Wilson plot of X1 vs Y1, and X2
vs. Y2 at Pr value of 4.5 is shown in Figure 12 and Figure 13,
respectively.
5.2 Nusselt number correlation
The following correlations have been developed using the
value of ‘p’ and ‘c’ obtained from the above graphs.
Figure 13. Logarithmic Plot for 60/60 plate at Pr = 4.5
6. CONCLUSIONS
The simulation was carried out to develop the generalized
Nusselt number correlations for a commercial plate heat
exchanger configuration using water as the working fluid for
both hot and cold sides. We chose hot side fluid as our
reference fluid, therefore only behaviour of hot side fluid to
changing conditions was observed. Hot side Nusselt number
was found to increase with increasing Reynolds number as
well as by increasing the chevron angle. Prandtl number,

209
however, does not affect the Nusselt number by a [11] Hazmi A.S.A., Maurad Z.A., Pauzi N.N.P.N., Idris Z.
considerable amount. Since it depends mainly on temperature (2016). Rapid evaluation of plate heat exchanger
i.e. higher the average temperature, lower will be the Prandtl performance and fouling analysis in epoxidation of
number, therefore working on lower Prandtl number is oleochemical at pilot plant scale, International
advisable as it yields better heat transfer result. Our presented Journal of Heat and Technology, Vol. 34, No. 4, pp.
correlations are valid for 500<Re<2500 and 3.5<Pr<7.5. 558-564. DOI: 10.18280/ijht.340402
[12] Doohan R.S., Kush P.K., Maheshwari G. (2016).
Exergy based optimization and experimental
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